Ideal Boilers Classic FF 330, Installation And Servicing

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Page 2: ...btain the gas consumption at a different calorific value a FOR L S divide the gross heat input kW by the gross C V of the gas MJ m3 b FOR FT 3 H divide the gross heat input Btu h by the gross C V of the gas Btu ft3 Table 1 General Data Table 2 Performance Data The value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has b...

Page 3: ...stalled to comply with Building Regulations can be demonstrated by completing and signing the Benchmark log book CONTENTS Air Supply 6 Boiler Clearances 5 Boiler Exploded View 11 Burner Exploded View 38 Control Box Exploded View 38 Electrical Connections 22 Electrical Regulations 7 Extension Ducts Fitting 20 External Control 22 FaultFinding 35 Flue Installation 6 Rear installation 14 Side installa...

Page 4: ...rcury or CFCs are included in any part of the boiler LOCATION OF BOILER The boiler must be installed on a flat and vertical wall capable of adequately supporting the weight of the boiler and any ancillary equipment The boiler may be fitted on a combustible wall and insulation between the wall and the boiler is not necessary unless required by the local authority The boiler must not be fitted outsi...

Page 5: ... fit or remove the casing during installation and subsequent servicing is impaired by pelmets etc this operation can be made easier by first removing the controls pod casing in line with the following instructions a Release the controls pod casing fixing screws a 3 full turns only Remove the pod by pulling it forward to disengage from the keyhole slots b Undo the 2 screws b retaining casing to the...

Page 6: ...l is exposed to external air 2 It is important that the position of the terminal allows the free passage of air across it at all times 3 Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Table 3 4 Where the lowest part of the terminal is fitted less than 2m 6 6 above a balcony above ground or above a flat roof to which people have access then th...

Page 7: ...all valves be in the closed position The following notes are for general guidance 1 It is NOT necessary to have a purpose provided air vent in the room or internal space in which the boiler is installed 2 If the boiler is to be installed in a cupboard or compartment permanent air vents are required for cooling purposes in the cupboard compartment at both high and low levels The air vents must eith...

Page 8: ...on Ideal Limited Note A cold water feed must be available back to the boiler when all automatic valves are in the closed position refer to BS 6798 and when close coupled the feed must not be in a vertical leg The Classic range of boilers can be installed in low head situations by fitting a surge arrester in the expansion pipe as shown The following conditions MUST be observed 1 The surge arrester ...

Page 9: ...xpansion Vessel a A diaphragm type expansion vessel must be connected at a point close to the inlet side of the pump the connecting pipe being not less than 15mm 1 2 nominal size and not incorporating valves of any sort b The vessel capacity must be adequate to accept the expansion of the system water when heated to 110 o C 230 o F c The charge pressure must not be less than the static water head ...

Page 10: ...ween them the stop valve being located between the system and the automatic air vent The stop valve may remain open during normal operation of the system if automatic water make up is required b Through a self contained unit comprising a cistern pressure booster pump if required and if necessary an automatic pressure reducing valve and flow restrictor The cistern should be supplied through a tempo...

Page 11: ... 330 shown LEGEND 1 Heat exchanger 2 Flue baffles 3 Hook bolts 4 Flow pipe assy 5 Return pipe assy 6 Collector hood assembly 7 Combustion chamber 12 Main burner 19 Control box cla 6115 59 24 Pressure switch 30 Fan 40 Wall mounting plate 52 Back panel 56 Baffle plate 350 360 only 59 Limit thermostat INSTALLATION ...

Page 12: ...tion kit Cl 1724 Hardware Pack Contents 50mm x No 14 wood screw 4 off 50mm x No 10 wood screw 8 off Wall plug 12 off M8 washer 1 off M5 wing nut 3 off Sealing plate 1 off M8 x 12 Hx Hd screw 1 off The boiler is supplied fully assembled in Pack A together with a standard flue assembly for lengths up to 600mm 23 1 2 rear or side flue outlet in Pack B Unpack and check the contents Pack B Contents Duc...

Page 13: ...on frame to ease handling and installation 4 Unpack the boiler terminal box and if applicable the extension flue box es 9 PACKAGING AND CASING REMOVAL SIDE FLUE INSTALLATION REAR FLUE INSTALLATION FLUEKITS Pack B supplied as standard Pack D optional extension kit for side flue or rear flue outlet Refer to Flue Extension Ducts A maximum of 1 extension duct plus the standard flue duct may be used to...

Page 14: ...e following a The wall mounting plate screw positions choose one from each group Note Mark the centre of the flue hole as well as the circumference b The position of the flue duct hole 5 Remove the templates from the wall IMPORTANT Ensure that during the cutting operation masonry falling outside of the building does not cause damage or personal injury 1 Cut the flue hole preferably with a 125mm 5 ...

Page 15: ... aligns with the groove on the outer flue duct This ensures correct alignment of the flue terminal 4 Stick the self adhesive foam strip provided in the hardware pack onto the flue immediately behind the boiler sealing ring 17 WALL MOUNTING PLATE 1 Fix the mounting plate to the wall with the No 14 x 50mm wood screws 2 Check with a spirit level that the plate is horizontal 3 Cupboard Supports In som...

Page 16: ...to the wall plug Use the washer and rectangular sealing plate to seal the slot and retain the boiler Note Before fully tightening the retaining screw check the boiler alignment using a spirit level and adjust as necessary with the jacking screw 19 CONNECTING THE FLUE TO THE BOILER 20 TERMINAL WALL PLATE This plate allows neat concealment and full compression of the rubber seal Its use is not essen...

Page 17: ... insert the plastic plugs provided for the wall mounting plate 3 Drill 1 further hole below the wall plate fixing screws in the position shown on the template for boiler fixing with the same 8mm 5 16 masonry drill and insert the plastic plug provided 4 Drill 4 holes with a 7mm 9 32 masonry drill and insert the plastic plugs provided for the side mounting plate 22 WALL MOUNTING TEMPLATE 1 Separate ...

Page 18: ...ut square mark the flue all the way round 4 Insert the cardboard duct ring for support and cut to length 5 Remove cardboard duct ring and remove any burrs 1 Fit the boiler sealing ring inside the outer flue duct Ensure the boiler sealing ring is fully engaged Ensure the notch aligns with the groove on the outer flue duct This ensures correct alignment of the flue terminal 2 Drill 3 holes 3 2mm 1 8...

Page 19: ... the mounting plate to the wall with the No 14 x 50mm wood screws 2 Check with a spirit level that the plate is horizontal 3 Cupboard Supports In some applications existing wooden supports may hinder the removal of the casing 2 cupboard supports are provided for the top and bottom of the opening These should be positioned to allow the casing to be removed in servicing 28 FITTING THE SIDE OUTLET PL...

Page 20: ... the flue extension tube and engage onto the fan elbow and secure with the screw attached to the elbow Note The sealing ring studs will locate in the back panel one way only This will ensure that the terminal grille is correctly aligned This plate allows neat concealment and full compression of the rubber seal Its use is not essential if the flue hole and flue ducts have been accurately cut and th...

Page 21: ...NG THE KIT 1 Remove the cardboard support aid from the flue and place safely to one side 2 Fit the inner flue extension duct onto the inner flue duct 3 Fit the outer flue extension duct onto the outer air duct 4 Drill 3 3 2mm 1 8 dia holes through the outer air duct Do not drill the inner flue duct 5 Insert the self tapping screws provided to fix the air duct in position Flue length Accessories Pr...

Page 22: ...erved 1 Controls that switch the system on or off e g a time switch must be wired in series in the live mains lead to the boiler 2 Controls that override an on off control e g frost thermostat must be wired into the mains lead in parallel with the control s to be overridden Refer to Frame 43 3 If a proprietary system is used follow the instructions supplied by the manufacturer 4 System designs fea...

Page 23: ...controlled system set the boiler thermostat to maximum 4 Switchmaster Midi is similar in operation but the wiring differs slightly see the manufacturer s literature 40 PICTORIAL WIRING LEGEND b blue bk black br brown r red y yellow w white or orange v violet p pink gy grey y g yellow green 41 MID POSITION VALVE Pumped only LEGEND b blue bk black br brown r red y yellow w white or orange v violet p...

Page 24: ...will be left off for more than a day or so then a frost thermostat should be wired into the system This is usually done at the programmer in which case the programme selector switches are set to OFF and all other controls MUST be left in the running position The frost thermostat should be sited in a cold place but where it can sense heat from the system Wiring should be as shown with minimal distu...

Page 25: ...ove the controls support casing Release the controls support front fixing screws 3 turns only Remove the pod by pulling it forward to disengage from the keyhole slots b Remove the control box securing screws and swing it down into the servicing position See diagram B 4 Slacken the screw in the burner pressure test point F and connect a gas pressure gauge via a flexible tube 5 Swing the control box...

Page 26: ...ONCE A YEAR In IE servicing work must be carried out by a Competent Person 11 As the installer you may wish to undertake the service contract yourself or alternatively offer to the customer the benefits of the Caradon Ideal Services scheme details of which are outlined in the household pack supplied with this boiler After completing the installation and commissioning of the system the installer sh...

Page 27: ...f this is the case and the gas input is at least 90 of the nominal then no further action need be taken If not proceed to paragraph c c Clean the main burner Refer to Frame 51 d Clean the heat exchanger Refer to Frame 52 e Clean the main and pilot injectors Refer to Frame 53 49 SCHEDULE f Remove any debris from inside the base of the casing g Check that the flue terminal is unobstructed and that t...

Page 28: ...oved jointing compound sparingly 4 Inspect the pilot burner and ignition detection electrode Ensure that they are clean and in good condition Check that a The pilot burner injector is not blocked or damaged Refer to Frame 60 for removal details b The pilot burner is clean and unobstructed c The ignition detection electrode is clean and undamaged d The ignition detection lead is in good condition e...

Page 29: ...Relight in accordance with Initial Lighting Frame 45 Note In order to assist fault finding the control box printed circuit board is fitted with 2 indicator lights which represent the following boiler conditions Neon I3 Mains electricity ON Neon SG1 Flashes to indicate ignition operation stops after detection The boiler MUST NOT be operated if the casing is not fitted 57 SIGHTGLASS REPLACEMENT 1 Re...

Page 30: ...stor harness to the bottom panel of the control box if fitted and remove the strap 6 Remove the sensor from the heat exchanger pocket and unclip from the back panel 7 Remove the strain relief bush from the back panel base 8 Remove the sensor lead through the grommet in the control box 9 Replace and reassemble in reverse order ensuring the new cable strap is fitted and securing the thermistor harne...

Page 31: ...g washer is replaced when refitting the pilot injector 6 Replace the electrode and pilot shield retaining both with the electrode nut Check the spark gap 7 Reassemble in reverse order 8 Check the operation of the boiler 9 The pilot is factory set to maximum and no further adjustment is possible Ensure there is an inlet pressure of 20 mbar available Also check burner ignition and cross lighting SER...

Page 32: ... as required Ensure that a new copper sealing washer is used 5 Fit the new burner ensuring that the retention tab is correctly located in the air box slot and reassemble in reverse order 6 Check the burner for cross lighting and flame stability Note Refer also to Frame 74 of Exploded Views for illustration of the procedure detailed below 7 Remove the gas control manifold assembly 8 Remove the 4 sc...

Page 33: ...rubber tube from the rear of the collector hood 6 Slacken the two M5 nuts on the front tie rods releasing the tie rods from the combustion chamber 7 Remove the M5 central fixing screw at the rear of the collector hood and remove collector hood fan assembly 8 Remove the three M4 screws retaining the fan to the collector hood 9 Fit the new fan and reassemble in reverse order ensuring the fan leads a...

Page 34: ...gs if used are correctly refitted 15 Fully test all functions including water and gas soundness 69 HEAT EXCHANGER REPLACEMENT Note Refer to Frame 7 Boiler assembly Exploded view for illustration of the procedure detailed below 1 Refer to Frame 56 2 Remove the burner air box assembly Refer to Frame 51 3 Drain the system 4 Disconnect the water connections If compression fittings are used then cut th...

Page 35: ... blocked YES Replace gas valve NO Is there a supply on terminals of main gas valve YES NO YES NO NO Is there a supply on the fan connector at PCB Molex marked FAN YES YES NO NO Check the polarity of the mains supply Check the continuity of the ignition lead from connector to electrode Does the spark now cease when gas is lit Ensure pilot and main gas valve leads are not crossed over Is there a sup...

Page 36: ...sembly complete with sightglass assy insulation M5 x 16 dogpoint pozi pan hd FF 330 360 1 171 949 37 Controls casing door with Lighting Instructions 1 171 475 39 Casing seal pack complete with screws 1 171 479 45 386 144 Overheat thermostat 1 171 950 59 Limit thermostat 1 173 353 The following are parts commonly required due to damage or expendability Their failure or absence is likely to affect s...

Page 37: ...Classic Slimline FF Installation Servicing 37 SHORT LIST OF PARTS 71 SHORT PARTS LIST cla 6113 45 59 23 12 18 19 30 24 39 9 17 26 15 14 13 13 A 72 BOILER CASING ASSEMBLY ...

Page 38: ...r box and pilot assembly 12 Main burner 13 Main burner injector 16 Pilot shield 17 Gas control valve 42 Gas service cock 74 BURNER ASSEMBLY Exploded View LEGEND 19 Control box 21 Thermostat potentiometer 23 Printed circuit board 26 Thermostat knob 58 Mains on off switch 73 CONTROL BOX Exploded View ...

Page 39: ...Classic Slimline FF Installation Servicing 39 NOTES ...

Page 40: ... the design and performance of its products The right is therefore reserved to vary specification without notice The Ideal Boilers Technical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers and system specifiers For details of courses please ring 01482 498 432 CERTIFIED PRODUCT Manufactured under a BS EN ISO 9001 19...